Dielectric material with low dielectric loss

ABSTRACT

The invention provides a dielectric material with low dielectric loss. The dielectric material comprises (i) 40˜80 parts by weight of polyphenylene ether resin having a Mw of 1000˜7000, a Mn of 1000˜4000 and Mw/Mn=1.0˜1.8; (ii) 5˜30 parts by weight of bismaleimide resins; and (iii) 5˜30 parts by weight of polymer additives, wherein the dielectric material has Dk of 3.75˜4.0 and Df of 0.0025˜0.0045. The dielectric material is suitably used in prepregs and insulation layers of a circuit board, because it has high Tg, low thermal expansion coefficient, low moisture absorption and excellent dielectric properties such as Dk and Df.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates to a dielectric material with low dielectric loss, particularly to a resin composition.

2. Related Art

As developed with wireless transmission products and technologies of transmitting high frequency, epoxy resin and novolak resin cannot satisfied for the advance application, especially high frequency printed circuit board (PCB). Fluorine-containing resin can be used as PCB with low dielectric loss. However, fluorine-containing resin is expensive and not easy to work, and thus limited to the use of military and astrodynamics. In addition, polyphenylene ether (PPE) resin has excellent mechanical property and dielectric property such as Dk and Df Therefore, the PPE resin is preferable to be used a material for high frequency PCB.

However, because the PPE resin is a thermal plastic resin, as applied in a copper-clad laminate, it may has disadvantages as follows: it is not easy to work due to a high melting viscosity of PPE resin, interlayer film is easy released in a solvent clean step during a process for manufacturing PCB due to a poor solvent resistance of PPE resin, and it is not easy to operate above a temperature of 250° C. in soldering process due to melting point close to Tg. Therefore, PPE resin has to be modified by curing so as to meet the requirement of using in PCB.

Curing modification of PPE resin generally has two manners: PPE resin may become curable resin by introducing crosslinking active functional groups to molecular structure of PPE resin. Alternatively, PPE resin may become co-mixing curable composite material by introducing other curable resins to molecular structure of PPE resin with co-mixing modification or interpenetrating network technology. However, PPE resin is likely incompatible with the active functional groups or curable resins, because the polar difference exists in their chemical structures. Alternatively, PPE resin may lose the excellent properties, after it conducts curing modification with the active functional groups or curable resins.

Therefore, there is a need to develop a material has excellent dielectric properties and other properties such as high Tg, low coefficient of thermal expansion and low water absorption of PCB requirement. Also, the material can be applied in the manufacture of high frequency PCB.

SUMMARY OF THE INVENTION

An object of the invention is to provide a dielectric material with low dielectric loss, which has excellent dielectric properties, low coefficient of thermal expansion and low water absorption.

To accomplish the above object, there is provided a dielectric material with low dielectric loss, which comprises (i) 40˜80 parts by weight of polyphenylene ether resin having a Mw of 1000˜7000, a Mn of 1000˜4000 and Mw/Mn=1.0˜1.8; (ii) 5˜30 parts by weight of bismaleimide; and (iii) 5˜30 parts by weight of polymer additives, wherein the dielectric material has Dk of 3.75˜4.0 and Df of 0.0025˜0.0045.

In the dielectric material with low dielectric loss of the invention, the polyphenylene ether resin is represented by the formula

wherein Y represents at least one C, O and benzene ring or the combination.

In the dielectric material with low dielectric loss of the invention, bismaleimide resins are selected from groups consisting of

Phenylmethane maleimide

wherein n≧1;

Bisphenol A diphenyl ether bismaleimide

3,3′-dimethyl-5,5′-diethyl-4,4′-diphenylethane bismaleimide

and

1,6-bismaleimide-(2,2,4-trimethyl)hexane.

In the dielectric material with low dielectric loss of the invention, the polymer additives are selected from groups consisting of

Homopolymers of Butadiene

wherein y=70% and x+z=30%;

Random copolymers of butadiene and styrene

wherein y=30%, x+z=70% and w=≧1, and the amount of styrene=25 wt %;

Maleinized Polybutadiene

wherein y=28% and x+z=72%, the amount of maleic anhydride=8 wt %;

Butadiene-styrene-divinylbenzene copolymer; and

Styrene Maleic Anhydride copolymer

wherein X=1˜8 and n≧1.

In the dielectric material with low dielectric loss of the invention, it is preferable that crosslinking agent is added to increase crosslinking density of resins. The crosslinking agents with 40-80 parts by weight may be selected from the following groups consisting of

In the dielectric material with low dielectric loss of the invention, it is preferable that catalyst is added to increase reaction of crosslinking agents and other resins. The catalysts includes at least one peroxide having 116° C.-128° C. for a half life of 10 hours with 2-8 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents. The suitable peroxides comprise dicumyl peroxide, α,α′-bis(tert-butylperoxy)diisopropyl benzene and 2,5-di(tert-butylperoxy)-2,5-dimethyl-3-hexyne.

In the dielectric material with low dielectric loss, it is preferable that filler is added to increase thermal conductivity and mechanical strength, and reduce thermal expansion. The suitable fillers may be fused silica, sphere-shaped silica, talc and aluminum silicate.

In order to increase flame retardation of the dielectric material of the invention, halogen-containing flame retardants and flame retardants without halogen may be used. The halogen-containing flame retardants may comprise decabromodiphenyl ethane. The flame retardants without halogen may comprise phosphor-containing flame retardants and phosphates. The phosphor-containing flame retardants and phosphates are produced by ALBEMARLE CO., LTD. The phosphates are like tetrakis(2,6-dimethylphenyl) 1,3-phenytene bisphosphate. tetrakis(2,6-dimethylphenyl) 1,3-phenylene bisphosphate can be represented by the formula, [OC₆H₃(CH₃)₂]₂P(O)OC₆H₄OP(O)[OC₆H₃(CH₃)₂]₂

The foregoing and other objects, features and advantages of the present invention will be apparent to those skilled in the art from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

No Drawings

DETAILED DESCRIPTION OF THE INVENTION

In one aspect of the present invention, there is provided a thermal curable dielectric material to produce a prepreg in a successive process in the following examples 4-1 to 4-7. The process uses the dielectric material as a coating on a substrate which may be a fiberglass cloth. The apparatus for producing the prepreg includes a pasting tank wherein there are provided a plurality of rolls. The pasting tank is filled with the dielectric material. A roll of fiberglass cloth may enter the pasting tank and pass the plurality of rolls. The fiberglass cloth is sufficiently impregnated with the dielectric material, and then surplus dielectric material is removed by a metering roller. A heat treatment for curing the dielectric material and removing the solvent is required at 100° C. to 350° C. for 1 minute to 5 hours, preferably at 150° C. to 300° C. for 1 minute to 3 hours. The prepreg is Obtained after the cured dielectric material is cooled down and the fiberglass cloth is wrapped.

A double-sided copper-clad laminate is produced by providing several prepregs in a neat stack between two electrodeposited copper foils, conducting a hot pressing process under 40 to 900 psi, raising temperature from 80° C. to 200° C. in 30 minutes, and then hot pressing at 200° C. for 120 minutes, and then cooling down to room temperature in 30 minutes in a vacuum pressing machine. The prepreg includes a fiberglass cloth of electrical grade 2116 and the dielectric material. Generally, a double-sided copper-clad laminate with a thickness of 1.0 mm is produced by providing 4 sheets of prepregs in a neat stack between two electrodeposited copper foils, with a thickness of 1.5 mm is produced by providing 7 sheets of prepregs, and with a thickness of 2.0 mm is produced by providing 10 sheets of prepregs.

The dielectric material of the present invention may form a stable homogeneous solution in a solvent with a low boiling point. The properties of a copper-clad laminate with the dielectric material of the invention were determined including Tg, heat decomposition temperature, heat decomposition time, solder heat resistance (288° C.), thermal expansion coefficient, water absorption, thermal conductivity, dielectric constant, dielectric loss tangent and flammability according to IPC-TM-650 test method manual. The determining results show the copper-clad laminate with the dielectric material of the invention has high Tg, excellent dielectric properties such as Dk and Df, low water absorption, high thermal resistance and high thermal conductivity. The copper-clad laminate is suitable used as a substrate for electronic elements and IC package.

EXAMPLES

TABLE 1 INFLUENCE OF PPE RESIN AMOUNT EXAMPLE 4-1 AMOUNT OF PPE RESIN C1 C2 C3 C4 C5 C6 C7 PPE resin SA9000 60 52.5 45 41 37.5 34 22.5 BMI resin 5100 15 15 15 15 15 15 15 Polybutadiene Ricon100 10 10 10 10 10 10 10 Crosslinking TAIC 15 22.5 30 34 37.5 41 52.5 agents Flame XP7866, phr 20 20 20 20 20 20 20 retardants fillers Fused silica, 20 20 20 20 20 20 20 phr catalysts Peroxide 2.5 2.5 2.5 2.5 2.5 2.5 2.5 119° C. for a half life of 10 hrs Tg, TMA IPC-TM-650 206 224 229 221 212 213 212 2.4.24.3 coefficient of IPC-TM-650 58/334 60/305 56/251 53/247 56/211 61/204 55/245 thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./ 0.29 0.33 0.34 0.34 0.39 0.39 0.40 absorption 1 hr 288° C. Dip288° C. >600 >600 >600 >600 >600 >600 >600 thermal resistance Dk(2-10 GHz) Cavity 3.93 3.89 3.89 3.89 3.90 3.86 3.87 Df(2-10 GHz) Cavity 0.0057 0.0054 0.0048 0.0044 0.0040 0.0040 0.0039 flammability UL94 V-0 V-0 V-0 V-0 V-0 V-0 V-0

Tg, Dk and Df were compared with different ratio and amount of PPE. The Tg level may be affected by the amount of PPE used. Also, the amount of PPE may also have an effect on the Dk and Df value. When the amount of PPE is high, Dk and Df may be high. When the amount of PPE is low, Dk and Df may be low. Typically, a low value for the Dk and Df is preferred. In addition, the thermal expansion coefficient may be raised when PPE is added, and BMI is added to balance the effect. In Table 1, part number SA9000 of PPE with chemical name of Polyphenylene Oxide (PPO) or Polyphenylene Ether (PPE) is produced by Sabic CO., LTD.

TABLE 2 INFLUENCE OF BMI RESIN SPECIES AND AMOUNT EXAMPLE 4-2 BMI RESIN A1 A2 A3 A4 A5 A6 A7 A8 PPE resin SA9000 42.5 40 37.5 35 32.5 37.5 37.5 37.5 BMI resin 2300 0 0 0 0 0 0 15 0 4000 0 0 0 0 0 15 0 0 5100 5 10 15 20 25 0 0 0 TMH 0 0 0 0 0 0 0 15 Polybutadiene Ricon100 10 10 10 10 10 10 10 10 Crosslinking TAIC 42.5 40 37.5 35 32.5 37.5 37.5 37.5 agents Flame XP7866, 20 20 20 20 20 20 20 20 retardants phr fillers Fused 20 20 20 20 20 20 20 20 silica, phr catalysts Peroxide 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 119° C. for a half life of 10 hrs Tg, TMA IPC-TM-650 210 212 212 211 211 212 222 195 2.4.24.3 Coefficient of IPC-TM-650 60/296 58/250 56/211 54/207 50/197 55/260 45/170 45/288 thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./ 0.30 0.34 0.39 0.44 0.46 0.41 0.47 0.33 absorption 1 hr 288° C. Dip288° C. >600 >600 >600 >600 >600 >600 >600 >600 thermal resistance Dk(2-10 GHz) Cavity 3.85 3.87 3.90 3.94 3.98 3.91 3.93 3.86 Df(2-10 GHz) Cavity 0.0040 0.0041 0.0040 0.0042 0.0043 0.0042 0.0046 0.0041 flam- UL94 V-0 V-0 V-0 V-0 V-0 V-1 V-0 V-0 mability BMI RESIN Compar-ative A9 A10 A11 A12 A13 A14 A15 example PPE resin SA9000 37 37 37 37 37 37.5 37 50 BMI resin 2300 8 0 8 0 0 5 4 0 4000 8 8 0 8 0 5 4 0 5100 0 8 0 0 8 5 4 0 TMH 0 0 8 8 8 0 4 0 Polybutadiene Ricon100 10 10 10 10 10 10 10 0 Crosslinking TAIC 37 37 37 37 37 37.5 37 50 agents Flame XP7866, 20 20 20 20 20 20 20 20 retardants phr fillers Fused 20 20 20 20 20 20 20 20 silica, phr catalysts Peroxide 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 119° C. for a half life of 10 hrs Tg, TMA IPC-TM-650 208 204 205 200 214 210 207 218 2.4.24.3 Coefficient of IPC-TM-650 50/210 57/278 45/230 52/268 54/290 53/240 49/225 64/325 thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./ 0.43 0.42 0.41 0.36 0.44 0.40 0.39 0.33 absorption 1 hr 288° C. Dip288° C. >600 >600 >600 >600 >600 >600 >600 >600 thermal resistance Dk(2-10 GHz) Cavity 3.96 3.91 3.90 3.87 3.89 3.91 3.90 3.80 Df(2-10 GHz) Cavity 0.0041 0.0041 0.0045 0.004 0.0039 0.0041 0.0043 0.0044 flam- UL94 V-0 V-0 V-0 V-0 V-0 V-0 V-0 V-0 mability

The coefficient of thermal expansion was measured with different species and amount of BMI resin. The more the amount of BMI resin is, the lower the coefficient of thermal expansion is. In the example, there are three kinds of comparison comprising three groups that A1-A5 shows different amount of BMI with the same species, A6-A8 shows the same amount of BMI with different species and A9-A15 shows about the same total amount of BMI with more than two species. In Table 2, part numbers 2300, 4000, 5100 and TMH of BMI are produced by Daiwakasei Industry CO., LTD, in which part number 2300 has chemical name of phenyl methane maleimide, part number 4000 has chemical name of 2,2′-bis[4-(4-maleimidophenoxy)phenyl]propane, part number 5100 has chemical name of 3,3′-dimethyl-5,5′-diethyl-4,4′-diphenylmethane bismaleimide and part number TMH has chemical name of 1,6′-bismaleimide-(2,2,4-trimethyl)hexane.

It can be found from group A1-A5 that by increasing the amount of BMI resin, the thermal expansion coefficient would decrease. However, by increasing the amount of BMI resin, the water absorption would also increase. As to group A6-A8, different BMI resins may reduce the thermal expansion coefficient, but would also affect the water absorption. Regarding group A9-A15, different combination of BMI resins may reduce the thermal expansion coefficient, and affect the water absorption also. In the invention, the object of addition of BMI to the dielectric material is to reduce the thermal expansion coefficient. However, the more the amount of BMI resin is, the higher the water absorption is. Therefore, the polymer additives are added to reduce the water absorption.

TABLE 3 INFLUENCE OF POLYMER ADDITIVES SPECIES AND AMOUNT EXAMPLE 4-3 POLYMER ADDITIVES B1 B2 B3 B4 B5 B6 B7 PPE resin SA9000 40 37.5 35 32.5 30 37.5 37.5 BMI resin 5100 15 15 15 15 15 15 15 Polybutadiene Ricon100 5 10 15 20 25 0 0 Ricon130MA8 0 0 0 0 0 10 0 Ricon150 0 0 0 0 0 0 10 Ricon257 0 0 0 0 0 0 0 SMA S:M = 3:1 0 0 0 0 0 0 0 S:M = 4:1 0 0 0 0 0 0 0 S:M = 5:1 0 0 0 0 0 0 0 S:M = 6:1 0 0 0 0 0 0 0 S:M = 8:1 0 0 0 0 0 0 0 Crosslinking TAIC 40 37.5 35 32.5 30 37.5 37.5 agents Flame retardant XP7866, phr 20 20 20 20 20 20 20 Fillers Fused silica, phr 20 20 20 20 20 20 20 catalysts Peroxide 119° C. 2.5 2.5 2.5 2.5 2.5 2.5 2.5 for a half life of 10 hrs Tg, TMA IPC-TM-650 221 212 200 194 186 213 217 2.4.24.3 coefficient of IPC-TM-650 53/201 56/211 64/220 67/260 74/300 58/265 57/270 thermal expansion 2.4.24 (α1/α2), ppm/° C. water absorption PCT/121° C./1 hr 0.43 0.39 0.35 0.32 0.28 0.45 0.43 288° C. thermal Dip288° C. >600 >600 >600 >600 >600 >600 >600 resistance Dk(2-10 GHz) Cavity 3.93 3.90 3.87 3.86 3.84 3.92 3.90 Df(2-10 GHz) Cavity 0.0043 0.0040 0.0041 0.0040 0.0039 0.0045 0.0044 flammability UL94 V-0 V-0 V-0 V-1 V-1 V-0 V-0 POLYMER ADDITIVES Comparative B9 B10 B11 B12 B13 example PPE resin SA9000 37.5 37.5 37.5 37.5 37.5 42.5 BMI resin 5100 15 15 15 15 15 15 Polybutadiene Ricon100 0 0 0 0 0 0 Ricon130MA8 0 0 0 0 0 0 Ricon150 0 0 0 0 0 0 Ricon257 0 0 0 0 0 0 SMA S:M = 3:1 10 0 0 0 0 0 S:M = 4:1 0 10 0 0 0 0 S:M = 5:1 0 0 10 0 0 0 S:M = 6:1 0 0 0 10 0 0 S:M = 8:1 0 0 0 0 10 0 Crosslinking TAIC 37.5 37.5 37.5 37.5 37.5 42.5 agents Flame retardants XP7866, phr 20 20 20 20 20 20 fillers Fused silica, phr 20 20 20 20 20 20 catalysts Peroxide 119° C. 2.5 2.5 2.5 2.5 2.5 2.5 for a half life of 10 hrs Tg, TMA IPC-TM-650 220 215 210 206 195 222 2.4.24.3 coefficient of IPC-TM-650 45/232 48/237 50/245 51/240 53/260 45/200 thermal expansion 2.4.24 (α1/α2), ppm/° C. water absorption PCT/121° C./1 hr 0.46 0.45 0.43 0.43 0.40 0.56 288° C. thermal Dip288° C. >600 >600 >600 >600 >600 >600 resistance Dk(2-10 GHz) Cavity 3.95 3.95 3.93 3.91 3.90 3.93 Df(2-10 GHz) Cavity 0.0085 0.0073 0.0064 0.0056 0.0042 0.0043 flammability UL94 V-0 V-0 V-0 V-0 V-0 V-0

The water absorption was measured with different species and amount of polymer additives. Polybutadiene (PB) and styrene-maleic anhydride (SMA) were used as the polymer additives in the invention. It can be found from using the different amount of PB with the same species that by increasing the amount of PB, the water absorption would decrease. However, with the increasing amount of PB, the coefficient of thermal expansion would also increase. As to using different species of PB in combination with SMA, it shows SMA can reduce the water absorption and the coefficient of thermal expansion, but Df may remain high. However, PB can be used to reduce Df. In Table 3, part numbers Ricon100, Ricon130MA8, Ricon150 and Ricon257 of PB are produced by Sartomer CO., LTD, in which part number Ricon 100 has chemical name of butadiene styrene copolymer, part number Ricon130MA8 has chemical name of butadiene adducted with maleic anhydride, part number Ricon 150 has chemical name of polybutadiene resin and Ricon 257 has chemical name of polybutadiene grafted with styrene and benzene in toluene solution. In Table 3, SMA with S:M=3:1 indicates that the ratio of styrene to maleic anhydride is 3 to 1. Generally, the ratios are about 1:1˜12:1.

TABLE 4 INFLUENCE OF DIFFERENT SPECIES OF CROSSLINKING AGENTS CROSSLINKING AGENT EXAMPLE 4-4 D1 D2 D3 PPE resin SA9000 37.5 37.5 37.5 BMI resin 5100 15 15 15 polybutadiene Ricon100 10 10 10 Crosslinking TAC 37.5 0 0 agents TAIC 0 37.5 0 TBS 0 0 37.5 Flame XP7866, phr 20 20 20 retardants fillers Fused silica, phr 20 20 20 catalysts Peroxide 119° C. 2.5 2.5 2.5 for a half life of 10 hrs Tg, TMA IPC-TM-650 183 212 202 2.4.24.3 coefficient IPC-TM-650 59/273 56/211 50/250 of thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./1 hr 0.39 0.39 0.12 absorption 288° C. Dip288° C. >600 >600 >600 thermal resistance Dk(2-10 GHz) Cavity 3.95 3.90 3.75 Df(2-10 GHz) Cavity 0.0039 6.0040 0.0035 flammability UL94 V-0 V-0 V-0

The dielectric material of the invention may comprise at least one crosslinking agent with 40-80 parts by weight selected from the following groups consisting of Triallyl cyanurate (TAC), Triallyl isocyanurate (TAIC) and 4-tert-butylstyrene. The properties of a copper-clad laminate with the dielectric material of the invention were measured with different species of crosslinking agents. It can be found by using TAC that Tg and the coefficient of thermal expansion were poor, and water absorption, Dk and Df were of ordinary level. As to TAIC, all the properties of a copper-clad laminate with the dielectric material of the invention were of ordinary level. Regarding 4-tert-butylstyrene, the coefficient of thermal expansion, water absorption and Df were excellent, but Dk is low,

TABLE 5 INFLUENCE OF DIFFERENT SPECIES OF FLAME RETARDANTS FLAME RETARDANTS EXAMPLE 4-5 E1 E2 E3 E4 PPE resin SA9000 37.5 37.5 37.5 37.5 BMI resin 5100 15 15 15 15 polybutadiene Ricon100 10 10 10 10 Crosslinking TAIC 37.5 37.5 37.5 37.5 agents Flame Decabromodiphenyl 10 0 0 0 retardants Ethane, pbr XP7866, phr 0 20 15 10 Tetrakis(2,6-di- 0 0 5 10 methylphenyl) 1,3-phenylene bisphosphate, phr fillers Fused silica, phr 20 20 20 20 catalysts Peroxide 119° C. 2.5 2.5 2.5 2.5 for a half life of 10 hrs Tg, TMA IPC-TM-650 224 212 226 180 2.4.24.3 coefficient IPC-TM-650 55/233 56/211 65/267 67/339 of thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./1 hr 0.43 0.39 0.37 0.30 absorption 288° C. Dip288° C. >60 >600 >600 >600 thermal resistance Dk(2-10 GHz) Cavity 3.83 3.90 3.87 3.85 Df(2-10 GHz) Cavity 0.0043 0.0040 0.0040 0.0037 flammability UL94 V-0 V-0 V-0 V-0

If desired, the dielectric material of the invention may optionally comprise flame retardants. A halogen-containing flame retardant of decabromodiphenyl ethane with 7-15 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents may be added to the dielectric material of the invention. The dielectric material of the invention may comprise at least one flame retardant without halogen with 12-14 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents selected from the following groups consisting of phosphor-containing flame retardants and phosphates. The phosphor-containing flame retardants and phosphates are produced by ALBEMARLE CO., LTD. The phosphates are like tetrakis(2,6-dimethylphenyl) 1,3-phenylene bisphosphate.

TABLE 6 INFLUENCE OF DIFFERENT SPECIES OF FILLERS EXAMPLES 4-6 FILLERS F1 F2 F3 F4 F5 F6 F7 PPE resin SA9000 37.5 37.5 37.5 37.5 37.5 37.5 37.5 BMI resin 5100 15 15 15 15 15 15 15 polybutadiene Ricon100 10 10 10 10 10 10 10 Crosslinking TAIC 37.5 37.5 37.5 37.5 37.5 37.5 37.5 agents Flame XP7866, phr 20 20 20 20 20 20 20 retardants fillers Fused silica, 0 20 10 10 30 25 45 phr Ball type 20 0 10 0 0 0 0 silica catalysts Peroxide 2.5 2.5 2.5 2.5 2.5 2.5 2.5 119° C. for a half life of 10 hrs Tg, TMA IPC-TM-650 210 212 214 220 208 215 195 2.4.24.3 coefficient of IPC-TM-650 53/220 56/211 52/225 58/260 45/210 50/220 40/205 thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./1 hr 0.41 0.39 0.40 0.39 0.38 0.40 0.36 absorption 288° C. thermal Dip288° C. >600 >600 >600 >600 >600 >600 >600 resistance Dk(2-10 GHz) Cavity 3.87 3.90 3.88 3.85 3.96 4.01 4.06 Df(2-10 GHz) Cavity 0.0039 0.0040 0.0040 0.0040 0.0041 0.0043 0.0045 flammability UL94 V-0 V-0 V-0 V-0 V-0 V-0 V-0

The dielectric material of the invention may optionally comprise fillers. The suitable fillers such as fused silica and sphere-shaped silica may be used. The suitable amount of filler is 8-50 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents. It can be found from the fused silica and the sphere-shaped silica with the same amount that the sphere-shaped silica has lower Dk and Df than the fused silica.

TABLE 7 INFLUENCE OF DIFFERENT AMOUNT AND SPECIES OF CATALYSTS EXAMPLE 4-7 CATALYSTS G1 G2 G3 G4 PPE resin SA9000 37.5 37.5 37.5 37.5 BMI resin 5100 15 15 15 15 polybutadiene Ricon100 10 10 10 10 Crosslinking TAIC 37.5 37.5 37.5 37.5 agents Flame XP7866, phr 20 20 20 20 retardants fillers Ball type silica 20 20 20 20 catalysts Peroxide 116° C. for a 0 0 0 0 half life of 10 hrs Peroxide 119° C. for a 2.5 3 7 8 half life of 10 hrs Peroxide 128° C. for a 0 0 0 0 half life of 10 hrs Tg, TMA IPC-TM-650 212 220 222 227 2.4.24.3 coefficient of IPC-TM-650 56/211 53/225 49/220 50/180 thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./1 hr 0.39 0.43 0.47 0.60 absorption 288° C. thermal Dip288° C. >600 >600 >600 >600 resistance Dk(2-10 GHz) Cavity 3.90 3.91 3.90 3.96 Df(2-10 GHz) Cavity 0.0040 0.0042 0.0045 0.0049 flammability UL94 V-0 V-0 V-0 V-0 CATALYSTS G5 G6 G7 G8 G9 PPE resin SA9000 37.5 37.5 37.5 37.5 37.5 BMI resin 5100 15 15 15 15 15 polybutadiene Ricon100 10 10 10 10 10 Crosslinking TAIC 37.5 37.5 37.5 37.5 37.5 agents Flame XP7866, phr 20 13 13 13 13 retardants fillers Ball type silica 20 13 13 13 13 catalysts Peroxide 116° C. for a 2.5 0 1.5 1.5 1 half life of 10 hrs Peroxide 119° C. for a 0 0 0 1.5 1 half life of 10 hrs Peroxide 128° C. for a 0 2.5 1.5 0 1 half life of 10 hrs Tg, TMA IPC-TM-650 208 225 220 209 215 2.4.24.3 coefficient of IPC-TM-650 57/230 50/230 47/226 52/220 50/235 thermal 2.4.24 expansion (α1/α2), ppm/° C. water PCT/121° C./1 hr 0.42 0.38 0.40 0.42 0.38 absorption 288° C. thermal Dip288° C. >600 >600 >600 >600 >600 resistance Dk(2-10 GHz) Cavity 3.88 3.91 3.92 3.93 3.91 Df(2-10 GHz) Cavity 0.0039 0.0040 0.0041 0.0042 0.0039 flammability UL94 V-0 V-0 V-0 V-0 V-0

The dielectric material of the invention may optionally comprise catalysts including peroxides having 116° C.-128° C. for a half life of 10 hours. The suitable amount of peroxide is 2-8 phr based on the total weight of PPE, BMI, polymer additives and crosslinking agents. The preferable catalyst is a peroxide having 119° C. for a half life of 10 hours.

The dielectric material of the invention may comprise PPE, but not comprise epoxy resin. The desired values of Dk and/or Df cannot be obtained, if epoxy resin is added to the dielectric material of the invention. When reacting epoxy resin with the dielectric material of the invention, the open rings of the epoxy resin may produce excess OH groups, therefore causing the Dk and Df value to remain high and unable to decrease. 

What is claimed is:
 1. A dielectric resin composition with low dielectric loss comprising: (i) 40-80 parts by weight of polyphenylene ether (PPE) resin having a Mw of 1000-7000, a Mn of 1000-4000 and Mw/Mn=1.0-1.8; (ii) 5-30 parts by weight of bismaleimide resins; and (iii) 5-30 parts by weight of polymer additives, wherein the dielectric resin composition has Dk of 3.75-4.0 and Df of 0.0025-0.0045, wherein polyphenylene ether resin is represented by the formula

wherein Y represents at least one C, O and benzene ring or the combination.
 2. The dielectric resin composition with low dielectric loss of claim 1, wherein bismaleimide resins are selected from groups consisting of phenylmethane maleimide

wherein n≧1; bisphenol A diphenyl ether bismaleimide

3,3′-dimethyl-5,5′-diethyl-4,4′-diphenylethane bismaleimide

and 1,6-bismaleimide-(2,2,4-trimethyl)hexane


3. The dielectric resin composition with low dielectric loss of claim 1, wherein the polymer additives are selected from groups consisting of: homopolymers of butadiene

wherein y=70% and x+z=30%; random copolymers of butadiene and styrene

wherein y=30%, x+z=70% and w=≧1, the amount of styrene=25 wt %; maleinized polybutadiene

wherein y=28% and x+z=72%, the amount of maleic anhydride=8 wt %; butadiene-styrene-divinylbenzene copolymer; and styrene maleic anhydride copolymer

wherein X=1^(˜)8 and n≧1. 